When faced with pitting corrosion in the Amine Regenerator Column, IGS HVTS provided an efficient, cost effective and long-term solution for Malaysian facility.
The challenge faced by the chemical ammonia plant involved their amine regenerator column, which experienced pitting corrosion in the unclad carbon steel area. Despite previous patchwork with organic coatings, the corrosion persisted, prompting the need for a long-term solution.
The plant explored two primary solutions for addressing pitting corrosion in the amine regenerator column: stainless steel cladding and complete column replacement. Both options were deemed expensive and time-consuming, causing additional two weeks+ of downtime, leading them to search for a more efficient and cost-effective alternative.
The decision-making process involved a meticulous evaluation, considering the plant’s HQ role as a technical authority overseeing various plants globally. After a year and a half of scrutiny and approval, the company selected IGS‘s thermal spray service HVTS (High Velocity Thermal Spray) as the preferred solution.
Being a technical authority, the company scrutinized the system extensively, addressing concerns and ensuring compliance. This involved prequalification of the alloy, case studies globally and within the APAC region, material understanding, and collaboration with the local partner in Malaysia, Klay EnerSol.
The IGS HVTS application commenced in September 2023. The application over a 76-square-meter area was executed efficiently, within only 4 1/2 days with IGS technicians working in nine shifts.
The key benefits for the chemical ammonia plant included the installation of a long-term corrosion barrier within a short timeframe, preventing further corrosion. Compared to alternatives like stainless steel cladding or column replacement, IGS High Velocity Thermal Spray saved the plant significant time and costs, potentially around $20 million.
The plant expressed satisfaction with the application, appreciating IGS’s unique technology. Since the successful project, the plant and its sister plants have shown interest in exploring IGS solutions for other equipment, showcasing a potential for future collaborations.
This case study demonstrates the effectiveness of IGS HVTS in providing innovative and efficient solutions for challenging corrosion issues in critical industrial equipment.
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